Suspension fabric seat heating system

ABSTRACT

A suspension fabric seat includes a fabric seat surface formed from a woven fabric material having heating element fibers. The heating element fibers are in electrical communication with a conductor. A carrier is overmolded onto the seat surface. The carrier and the conductor are disposed in a frame and a connector is mounted to the frame in electrical communication with the conductor.

CROSS-REFERENCE TO RELATED APPLICATION DATA

This application claims the benefit of and priority to Provisional U.S.Patent Application Ser. No. 62/714,173, filed Aug. 3, 2018, titled,“SUSPENSION FABRIC SEAT HEATING SYSTEM,” the entirety of which isincorporated herein by reference.

BACKGROUND

The present invention relates to suspension fabric seating and moreparticularly, to a suspension fabric seat heating system incorporated inthe seat fabric.

Suspension or suspended fabrics have come into common use as analternative to hard surfaces and foam padded surfaces for seating. Suchsuspension fabric seating surfaces can provide the comfort of foampadded surfaces in a weight similar to hard plastic seating and atrelatively low cost. Advantageously, suspension fabric seating providesenhanced comfort using a preset tension in the suspension fabric that isadjustable for reaction force for comfort needs, provides tensionzonally across the seating surface and is housed in a curved frame forstyling character and comfort profile in reclining kinematics.

Vehicle seating, however, is typically of the foam-padded type, and isdesigned for comfort. Such foam-padded seating includes a steelstructure and stamped components that are welded together to form aseating structure subassembly. A steel suspension layer that is belowthe occupant is added to bridge the distance between seat structurebeams. The steel suspension offers some hammocking between structurepillars in the seat structure to enhance comfort characteristics. Thefoam padding, such as polyurethane (PU) covers the steel structure andsuspension, and offers force vs. deflection compliance during use foroccupant comfort. In a typical configuration, the foam layer is coveredwith a trim cover that may include leather, vinyl, and/or polyestertextile fabric, a lofted fabric breathable layer and felt or a bondedlayer to prevent wrinkling. These layers are used generally to foraesthetics and to manage comfort requirements as well as G-forces duringa crash event.

Foam, however, has disadvantages in that although it provides comfort,it is difficult to heat. PU foams have a high R value or highlyinsulative properties that make it difficult to transfer heat from thevehicle cabin to the seating surface. The foams are typically also verythick 50-150 mm (about 2-6 inches) and are generally non-porous whichhinders air flow from the seat environment to the occupant's skin. Heatmodules are used to compensate for the R value of foam and the specificheat of seat trim covers in current automotive seats. Trim covers are,for example, leather, cloth, vinyl and the like that cover the foamcushions and add to the resistance to transfer cabin heat to theoccupant.

Suspension fabric seating can be heated using a number of approaches.One known way in which such seating is by use of a blower system. Forcedair that is conditioned (heated or cooled) can be funneled to blow onthe back side of the fabric. The porosity of the suspension fabricallows the forced air to heat or cool the occupant skin. The forced airoffers a cooling sensation to the seat user by drawing heat and humidity(by evaporative cooling) from the seat. The velocity of the air can bealtered using blower modules, and air temperature through forced airdevices can be conditioned to a targeted temperature to assist theheating or cooling function.

Another way in which suspension fabric seating can be heated is by useof a heating element that is sewn, welded or adhered to the back sidethe seat surface. This design, however, includes a barrier or distancebetween the occupant and the heating source creating an air gap. The airgap functions as an insulative layer, thus reducing the heatingefficiency of the heating element. Reduced efficiencies requireincreased power to the heating element—power which is taken from theoverall vehicle systems. This can be especially important with the shifttoward hybrid and fully electric vehicles.

In addition, mat heaters that are attached to back side of the seatsurface hinder suspension fabric stretch and limit the hammocking effectthat is required for seat comfort. That is, when hammocking isrestricted, comfort is reduced, adversely affecting thestretch/elongation of fabric fibers and altering the indentation forcedeflection (IFD) of the seat. Moreover, suspension seats with attachedheater modules can create hard points or non-uniform hard locations inthe suspended fabric, again, reducing occupant comfort. Further, heatingelement systems are costly due to the parts required and the laborneeded for assembly.

Another drawback to heating element systems is that the overallaesthetics of the seat can be impacted. If the fabric is quite porous,light colored or transparent/translucent the heating element may bevisible through the fabric. In addition, thermocouples and otherconnectors/conductors require wire harnesses that may be difficult toposition, and do not support a simple contemporary aesthetic.

Accordingly, there is a need for a suspension fabric seat heating systemthat is incorporated in the seat fabric. Desirably, such a systempermits heating the seat using less current (reduced amperage). Moredesirably still, such a system heats the seat close to an occupant'sskin so as to provide an efficient heating scenario, resulting inshorter heating times and reduced current draw. Still more desirably, insuch a system, the electronic circuit within the seat is minimally ornot visible by the vehicle occupants and does not impact the suspensionfabric flex so as to reduce occupant comfort.

SUMMARY

In one aspect a suspension seat includes a fabric seat surface formedfrom a woven fabric material with heating element fibers in the fabric.The heating element fibers are in electrical communication with aconductor. A carrier is overmolded onto the seat surface. The carrierand the conductor are disposed in a frame and a connector is inelectrical communication with the conductor.

Advantageously, a suspension seat in accordance with the presentdisclosure includes a heating system that is incorporated in thesuspension seat fabric. The system permits heating the seat using lesscurrent and heats the seat close to an occupant's skin to provide anefficient heating scenario.

In an embodiment, the heating element fibers are woven into the fabric.Alternately, the heating element fibers can be disposed on a surface ofthe fabric. The fabric is woven from warp fibers and weft fibers. In anembodiment, the heating element fibers are disposed alongside the warpfibers. The heating element fibers can replace some of the warp fibers.The heating element fibers may also replace some of the weft fibers.

The heating element fibers are in electrical communication with aconductor. In embodiments, the conductor can be a conductive strip andthe strip is positioned in a strip socket, with the heating elementfibers captured between the conductive strip and the strip socket.

A carrier is overmolded onto the seat surface. The carrier is disposedin a channel in the frame and the conductor is disposed in a channel inthe frame. In an embodiment the conductor can carrier are disposed in acommon channel in the frame.

In an embodiment the carrier and the conductor are overmolded onto theseat surface such that ends of the heating element fibers extend beyonda periphery of the carrier.

The carrier and conductor can be overmolded onto the seat surface suchthat ends of the heating element fibers extend beyond a periphery of thecarrier. The seat surface and carrier are disposed in the frame and aconnector is in electrical communication with the conductor.

In embodiments, the conductor is formed as part of the carrier. In anembodiment, the carrier is formed, in part by a conductive polymericmaterial and in another part by a non-conductive polymeric material. Thefabric is disposed between the conductive and non-conductive polymericmaterials. One suitable conductive polymeric material is a conductivethermoplastic material.

In an embodiment, the conductor is a powdered metal applied to thefabric. In such an embodiment, the carrier is overmolded over the fabricand the powdered metal. In another embodiment, the conductor is aconductive strip with the fabric in contact therewith. In thisembodiment, the carrier is overmolded over the fabric and conductivestrip. The frame can include a channel and the conductive strip can bepositioned in the channel.

In an embodiment, some of the fabric is formed from monofilaments. Themonofilaments can be formed from, for example, a block copolymer. Themonofilaments can be the weft fiber and can provide elasticity to theseat surface to obtain a desired occupant pressure map of the seat shapemaking the seat more comfortable.

In an embodiment, the heating element fibers have a targeted ohmresistance to achieve a temperature of about 30° C. to about 50° C. 15.In an embodiment, the seat can include a temperature sensor. Thetemperature sensor can be a fiber incorporated into the seat surface.

A method for making a seat includes overmolding a carrier onto a fabricseat surface formed from a woven fabric material having heating elementfibers. In a method, the heating element fibers are contacted with aconductor and the carrier and the conductor are positioned in a frame.In methods, the carrier is positioned in a channel in the frame and theconductor is positioned in a channel in the frame. In some methods theconductor and carrier are positioned in a common channel.

In some methods, ends of the heating element fibers extend beyond aperiphery of the carrier and the carrier is, in part, electricallyconductive. The frame is formed and the carrier is positioned in theframe.

In a method, overmolding the carrier onto the fabric is carried out in afirst overmolding of a conductive polymeric material onto which thefabric is positioned and a second overmolding of a non-conductivepolymeric material onto the fabric and the conductive polymericmaterial.

In another method overmolding the carrier onto the fabric is carried outin a first overmolding of a non-conductive polymeric material onto whichthe fabric having a powdered metal is positioned and a secondovermolding of a non-conductive polymeric material onto the fabric,powdered metal and the conductive polymeric material.

In still another method overmolding the carrier onto the fabric includesovermolding a non-conductive polymeric material onto the fabric and aconductive strip. In methods, the frame has a channel and a conductiveadhesive is disposed in the channel. The carrier is positioned on theadhesive with the ends of the heating element fibers in contact with theconductive adhesive.

The methods can all include positioning a connector on the frame inelectrical connection with the conductor.

These and other features and advantages of the present device will beapparent from the following description, taken in conjunction with theaccompanying sheets of drawings, and in conjunction with the appendedclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

The benefits and advantages of the present embodiments will become morereadily apparent to those of ordinary skill in the relevant art afterreviewing the following detailed description and accompanying drawings,wherein:

FIG. 1 is an example of a suspension seat fabric in accordance with thepresent disclosure;

FIG. 2 illustrates an embodiment of a seat bottom surface in a seatsurface carrier in accordance aspects of the present disclosure;

FIGS. 3A and 3B illustrate the basic construction of an embodiment ofthe seat bottom in an assembled view (FIG. 3A) and in an exploded view(FIG. 3B), showing the seat bottom surface in the carrier, the conductorand the seat frame;

FIG. 4 is an illustration of an embodiment of a seat surface showing theheating element fibers or electrical conductive wires woven into thefabric;

FIG. 5 illustrates a conductive strip and strip socket;

FIG. 6 is a perspective view of the strip socket;

FIG. 7 shows the conductive strip and the socket in position on oppositesides of the heating element fibers;

FIG. 8 illustrates the conductive strip and feed socket as theconductive strip is positioned for insertion into the strip socket withthe captured heating element fibers;

FIG. 9 illustrates trimming of the heating element fibers after theconducting strip and strip socket are engaged with the heating elementfibers;

FIG. 10 illustrates two ways in which the conductive strip and stripsocket (with the captured heating element fibers) can be mounted to theseat frame;

FIGS. 11A-11C are detailed views of the construction of an embodiment ofthe seat bottom, illustrating various routings of the conductor and anelectrical connector;

FIGS. 12A-12D show various examples of constructions of the heatingelement fibers in the seat frame; and

FIG. 13 is a flow diagram of a method for fabricating the suspensionfabric seat and heating system in accordance with the presentdisclosure.

DETAILED DESCRIPTION

While the present disclosure is susceptible of embodiment in variousforms, there is shown in the drawings and will hereinafter be describedone or more embodiments with the understanding that the presentdisclosure is to be considered illustrative only and is not intended tolimit the disclosure to any specific embodiment described orillustrated.

Referring to the figures and in particular to FIG. 1, there is shown anexample of a woven fabric 10 for a suspension fabric seat surface 12.The fabric 10 is woven from fibers or yarns (used interchangeablyherein) and includes a series of warp fibers 14, illustrated as thevertical fibers, and weft fibers 16 illustrated as the horizontalfibers. Typically, the warp fibers 14 are fill yarns and extend in thefront-to-rear direction of a seat bottom surface or a top-to-bottomdirection in a seat back surface or headrest. The weft fibers 16 aretypically monofilament fibers that extend in a side-to-side directiontransverse to the warp fibers 14. An example of a woven fabric isdisclosed in Coffield, U.S. Pat. No. 8,329,281, which patent is commonlyassigned with the present application, the disclosure of which isincorporated herein in its entirety. Examples of the monofilament fibersare disclosed in Coffield, et al., U.S. Pat. No. 8,857,033 and Coffield,U.S. Pat. No. 9,156,211, which patents are commonly assigned with thepresent application, the disclosures of which are incorporated herein intheir entirety.

The warp fibers 14 or yarns are relatively inelastic and elongate lessthan about 12 to 15 percent and preferably, less than about 5 percent.The warp fibers 14 give the fabric 10 bulk and thickness and are able tobe colored for a colored fabric suspension assembly. The warp fibers 14are used to shape the seat surface 12 by pulling the monofilament (weft)fibers 16 out of straight line position to form a parabolic shape in theoverall suspension fabric seat surface 10. The warp fibers 14 can beformed from, for example, a polyester yarn or like, suitable materials.

The weft fibers 16 are typically elastic and can be formed from, forexample, a block copolymer monofilament. These fibers 16 can beorientated and elongate more than 10 percent, and up to about 30 percentwhen measured on a stress strain curve. The monofilament weft fibers 16can be oriented and conditioned (as at an elevated temperature) and canbe treated zonally to obtain a desired occupant pressure map of the seatshape making the seat more comfortable.

As seen in FIG. 1, heating elements fibers or conductive wires 18 areinterspersed with the warp fill fibers or yarns 14. In embodiments, theheating element fibers 18 can replace all or some of the fill yarns 14or they can supplement the fill yarns 14. In embodiments, the heatingelement fibers 18 are semi-conductive with a targeted ohm resistance toachieve a temperature of about 30° C. to about 50° C. when powered. Someexamples of heating element fibers 18 are coated stainless steel wire,copper, nano-tube materials such as nano-tube polyester, carbon yarns,and the like. Other suitable heating element fibers 18 will berecognized by those skilled in the art. In some embodiments, some of theweft fibers 14 may include or be replaced by or supplemented withheating element fibers 18 as well.

As noted above, in an embodiment, the heating element fibers 18 arewoven in place of some of warp fibers or yarns so as to limit thatamount of added bulk and thickness, and to reduce the visual andaesthetic impact on the seat surface 12. It will be appreciated that theheating element fibers 18 can be affixed to the bottom of the seatsurface 12 as well, by, for example, stitching, adhesives and the like.In some embodiments the heating element fibers 18 can be woven into thefabric 10 having some amount of slack, as indicated at 11 in FIG. 4. Aswill be appreciated by those skilled in the art, the heating elementfibers 18 may be formed from materials that are less elastic than eitheror both of the warp and weft fibers. As such, in order to allow theheating element fibers 18 to conform to the seat surface 12 as the seatsurface 12 conforms to a user's body, slack 11 in the heating elementfibers 18 permits such conformance while preventing overstressing oroverstretching the heating element fibers 18.

Referring to FIGS. 4-10, in an embodiment, the heating element fibers 18are secured to a conductive member 19, such as a highly conductivestrip. The heating element fibers 18 can be secured to the conductivestrip 19 in a wide variety of ways. For example, a coating on theheating element fibers 18 can be removed and the bare heating elementfibers 18 can be soldered or otherwise adhered to the conductive strip.In an embodiment, as illustrated in FIGS. 5-8, the heating elementfibers 18 can be captured between the highly conductive strip 19 and areceiving element 21 configured to receive the heating element fibers 18and the conductive strip 19, such as the illustrated conductive stripsocket 21. In such an embodiment the conductive strip 19 and the stripsocket 21 can be configured, for example, roughened, to strip or removeany coating from the heating element fibers 18 as the conductive strip19 is inserted into the strip socket 21 with the heating element fibers18 captured therebetween. Such an arrangement serves to provide thenecessary electrical contact between the heating element fibers 18 andthe conductive strip 19.

The woven fabric 10 is overmolded with a carrier 22. The fabric 10 isinstalled into a carrier mold and the fabric 10 is overmolded with thecarrier 22 material. A carrier 22 material can be, for example, a blockcopolymer that is chemically similar to the fabric 10 monofilaments (theweft fibers 16). This permits chemical bonding during the injection moldprocess. Mechanical bonding also takes place during overmolding.Preferably, the heating element fibers 18 in the fabric 10 are designedas a parallel circuit for heating efficiency and robustness.

FIG. 2 illustrates an embodiment of a seat bottom surface 12 with acarrier 22 overmolded onto the seat surface fabric 10. In theillustrated embodiment, the seat bottom surface 12 and carrier 22 areshown with the heating element fibers 18 on either side of, and outsideof the carrier 22. In an embodiment, the heating element fibers 18 arewoven into the fabric 10, as illustrated in FIG. 1. In FIG. 2, theheating element fibers 18 are visible where the fibers 18 extend beyondthe carrier periphery 50. The heating element fibers 18 are continuous(to both sides of the seat and into the carrier 22) to complete theelectrical circuit. The heating element fibers 18 can be located in theseat surface 12 so as to minimize wear.

In the embodiment illustrated in FIG. 10, the heating element fibers 18do not extend beyond, and are not molded into, the carrier 22. Rather,the heating element fibers 18 are captured and pinched between theconductive strip 19 and the strip socket 21 within the perimeter orbounds of the carrier 22.

It will be understood that some types of heating element fibers 18 maybe coated fibers and that coated fibers 18, such as coated stainlesssteel fibers, have the coating removed so that an electrical circuit canbe completed. Removal of the coating can be, for example, by burnishingthe ends of the fibers 18, abrading during installation (as in theheating element fibers 18 and configuration of FIGS. 4-10), heating orother methods that will be recognized by those skilled in the art.Removing the coating exposes the conductive core of the heating elementfibers 18.

FIGS. 3A and 3B illustrate assembled and exploded views, respectively,of an embodiment of the seat surface 12 and carrier 22, the conductor 24and the frame 26. The conductor 24 is shown as a separate component, butas described herein in connection with certain embodiments, theconductor 24 may be incorporated into the carrier 22. In an embodiment,the conductor 24 is disposed in a channel 28 formed in the frame 26. Aconnector 30, shown in an exploded position, is electrically connectedto the conductor 24 to provide power and control to the heating elementsfibers 18. FIGS. 11A-C illustrate the negative and positive sides 32,34, respectively, of the conductor 24 as it is disposed in the channel28 and the electrical connector 30. The connector 30 is shown in bothfront and rear views of the frame 26.

FIG. 10 illustrates two ways in which the seat surface 12, carrier 22and conductor/heating element fibers (the conductive strip 19 and thestrip socket 21 with the captured heating element fibers 18) can beinstalled in the frame 26. On the left-hand side of FIG. 10, theconductive strip 19/heating element fibers 18/strip socket 21 and thecarrier 22 are installed in a common channel 28 in the frame, and bothare press fit into the channel 28 in the frame 26. On the right-handside of FIG. 10, the conductive strip 19/heating element fibers 18/stripsocket 21 is installed in a conductor channel 28′ in the frame 26, andthe carrier 22 is installed in a carrier channel 28 in the frame 26,separate from the conductor channel 28′. The conductive strip 19/heatingelement fibers 18/strip socket 21 and the carrier 22 can be press fitinto the channel 28/28′. Other ways in which the conductive strip19/heating element fibers 18/strip socket 21 and carrier 22 are securedin the frame 26 will be recognized by those skilled in the art. Onceinstalled and secured in the frame 26, electrical connection, forexample, power and control can be provided to the conductive strip19/heating element fibers 18/strip socket 21 as illustrated in FIGS.11A-11C.

In embodiments, temperature measurement or sensing is provided in theheating system. Referring briefly again to FIG. 1, in an embodiment, asensor, such as a temperature sensor is provided in the form of one ormore fibers 31. The temperature sensor fiber 31 can be, for example, athermocouple fiber that is incorporated into the seat surface 12, forexample along with the weft or monofilament fibers 16. It will beappreciated that the temperature sensor fiber 31 can also beincorporated along with the warp fibers 14, or as another fiber. Assuch, the temperature sensor fiber 31 can be fabricated to havecharacteristics similar to those fibers 14 or 16 around which it isincorporated into the seat surface 12. The temperature sensor fiber 31may be incorporated into the seat heating system along with a switch toprovide, isolate or vary power to the heating element fibers 18. Othersensors for temperature measurement may also be used, which othersensors are within the scope and spirit of the present disclosure. It iscontemplated that the heating element fibers 18 can be individuallycontrolled or monitored, or can be controlled in groups as well as beingcontrolled as one.

FIGS. 12A-12D illustrate various examples of ways in which the heatingelement fibers 18 as positioned in and extending through the carrier 22,can be electrically connected to the connector 30, through the frame 26.

FIG. 12A illustrates a conductor 24 that uses a conductive thermoplastic36 to which the heating element fiber 18 ends are connected. In anembodiment, the conductive thermoplastic 36 is part of the carrier 22overmold. That is, a first shot or application of the carrier 22overmold material is the conductive thermoplastic 36 with the exposedfibers 18 laid into the conductive thermoplastic 36. A second shot of anon-conductive thermoplastic 38 is molded over the fiber 18 ends and theconductive thermoplastic 36 to seal the fiber 18 ends and form a seatsurface/carrier assembly 48. The seat surface/carrier assembly 48 isthen positioned in the frame channel 28.

In FIG. 12B, a powdered metal 40 is applied to the fabric 10 and thecarrier 22 is overmolded onto the fabric 10 and the powdered metal 40.The powdered metal 40 bridges the spaces between the fibers 18, and theinjection pressure during the carrier 22 overmolding wets out thepowdered metal 40 to form the conductor 24. The seat surface/carrierassembly 48 is then positioned in the frame channel 28.

In FIG. 12C, a conductive foil element 42, such as a metal foil strip ispositioned in the carrier mold tool prior to positioning the fabric 10in the mold tool. The carrier 22 overmolding presses the foil 42 on tothe heating element fiber 18 ends to form the conductor 24, and the seatsurface/carrier assembly 48 is then positioned in the frame channel 28.

In FIG. 12D, a conductive adhesive 44 is used. In this embodiment theconductive adhesive 44, such as a conductive epoxy which can be applied,for example, in strip form, is positioned in the carrier tool before thefabric 10 is loaded. In the molding process, the injected carrier resinflows over the heating element fiber 18 ends and the adhesive 44, andthe injection pressure and resin heat cure the adhesive 44 and wet outonto heating element fiber 18 ends and the fabric 10 to form theconductor 24. Other suitable conductive adhesives 44 will be recognizedby those skilled in the art.

It will be appreciated that in each of the embodiments disclosed, theconductor 24, whether separate from or formed as part of the carrier 22,is reliably electrically attached to each of the heating element fibers18 across the entirety of the seat surface 12. It is anticipated thatabout 2 to 30 yarns, spaced about 10 to 30 mm apart will provide thedesired level of heating. The carrier 22 overmold holds the fabric 10 intension, and also conceals the conductive path, e.g., the conductor 24,from the heating element fibers 18 up to termination at the electricalterminal connector 30.

One method 100 for making the suspension fabric seat heating system isillustrated in FIG. 13, and includes, at step 102, cutting a wovenfabric 10 as needed and positioning the woven fabric 10 (with theheating element fibers 18 in the fabric 10) in a carrier 22 mold at step104. The carrier 22 is overmolded onto the fabric 10 at step 106 with ablock copolymer or other suitable polymeric material. Preferably, thecarrier overmold material is chemically similar to the fabricmonofilaments (for example, the weft fibers 16) so that chemical, aswell as mechanical bonding occurs during the injection molding process.

In a method, the carrier 22 overmold is carried out in a two shot or twoapplication process. In a first shot, the overmold material is aconductive thermoplastic 36. The fabric 10 with the heating elementfibers 18 is then laid onto the conductive thermoplastic 36 and a secondshot of a non-conductive thermoplastic 38 is laid over the fabric 10 andthe conductive thermoplastic 36.

In another method, the carrier 22 overmold is also carried out in a twoshot or two application process. In a first shot, the overmold materialis a non-conductive thermoplastic 38. A powdered metal 40 is applied tothe fabric 10 and the fabric 10 and powdered metal 40 are laid onto thenon-conductive thermoplastic 38. A second shot of non-conductivethermoplastic 38 is laid over the fabric 10 and metal 40, and the firstshot of non-conductive thermoplastic 38.

In still another method, the carrier 22 overmold is carried out in a oneshot or application process. A conductive element 42, such as a metalfoil or strip is positioned in the overmold tool, and the fabric 10,with the heating element fibers 18 is laid onto the element 42. Anon-conductive thermoplastic 28 is laid over the fabric 10 and theelement 42.

In yet another method, the carrier 22 overmold is carried out in a twoshot or two application process with the fabric 10 sandwiched betweentwo applications of non-conductive thermoplastic 38 to form the carrier22. The heat element fiber 18 ends are exposed beyond the carrier outerperiphery 50. A conductive adhesive 44 is applied to an outer surface ofthe carrier 22 or the bottom of the frame channel 28 so as to makecontact with the heat element fiber 18 exposed ends.

Once the fabric or seat surface/carrier assembly 48 is formed, in a postprocessing step at step 108, any insulative coating is removed from theheating element fibers 18 outside of the overmolded fabric/carrierassembly 48. The insulative coating, if present, can be removed byburnishing, heating or other suitable methods to expose the conductivecore of the heating element fibers 18. If necessary, the carrier 22 andfabric 10 can be trimmed to remove excess polymer beyond the carrierouter periphery 50 for better quality and fit into the frame 26. In somemethods, a small amount of fabric 10 with the exposed heating elementfiber 18 ends remains beyond the carrier outer periphery 50.

The frame 26 is molded so as to receive the seat surface/carrierassembly 48. In embodiments, the frame 26 is with the channel 28 and,depending upon which configuration of fabric/carrier assembly 48 isused, the conductor 24 may be applied or installed in the channel 28,preferably in the bottom of the channel 28, or the fabric/carrierassembly 48 which incorporates the conductor 24, is installed directlyinto the channel 28, as at step 110.

In a method, the burnished ends of the heating element fiber 18 arefolded over the carrier 22 to expose the conductive fibers to theconductor 24, as needed, and the fabric/carrier assembly 48 is installedinto the frame.

In still another method for making the suspension fabric seat heatingsystem, the fabric 10 is woven (with the heating element fibers 18 inthe fabric 10) such that the heating element fibers 18 do not extend tothe edges of the fabric 10. The heating element fibers 18 may be woveninto the fabric 10 with some slack. The heating element fibers 18 arecaptured between a conductive strip 19 and a strip receiver 21, such asthe illustrated strip socket, on either side of the fabric 10. Thecarrier 22 is overmolded onto the fabric 10 outside of the conductivestrip 19 and a strip receiver 21 with, for example, a block copolymer orother suitable polymeric material. Preferably, the carrier overmoldmaterial is chemically similar to the fabric monofilaments (for example,the weft fibers 16) so that chemical, as well as mechanical bondingoccurs during the injection molding process.

The carrier 22, and the conductive strip 19 and strip receiver 21 withthe captured heating element fibers 18, are then installed in thechannel 28 in the frame 26. The conductive strip 19/strip receiver21/captured heating element fibers 18 and the carrier 22 can beinstalled in common channels 28 or the conductive strip 19/stripreceiver 21/captured heating element fibers 18 can be installed in onechannel 28′ and the carrier in another channel 28.

Because the channel 28 or 28′ navigates around the frame 26 perimeterand terminates at the connector 30, preferably at a location hidden fromoccupant view and near the vehicle wire harness and wire harnessterminal connector, there are few if any visible components to detractfrom the aesthetics of the seat. In addition, the configuration in whichthe conductive strip 19/strip receiver 21/captured heating elementfibers 18 do not extend to and into the carrier, the channel 28 or 28′can serve as a protective zone of the seat, free of occupant inducedstresses and enhancing circuit robustness and the life span of theelectronics.

The molded in electrical connector 30 ensures easy installation of powerfor the electrical circuit, and maintains a discrete appearance hiddenfrom view within the seat frame assembly. The present configuration issufficiently robust to withstand repeated loading by vehicle seatoccupants.

In the present disclosure, the words “a” or “an” are to be taken toinclude both the singular and the plural. Conversely, any reference toplural items shall, where appropriate, include the singular. It will beappreciated by those skilled in the art that the relative directionalterms such as upper, lower, rearward, forward and the like are forexplanatory purposes only and are not intended to limit the scope of thedisclosure.

All patents or patent applications referred to herein, are herebyincorporated herein by reference, whether or not specifically done sowithin the text of this disclosure.

From the foregoing it will be observed that numerous modification andvariations can be effectuated without departing from the true spirit andscope of the novel concepts of the present film. It is to be understoodthat no limitation with respect to the specific embodiments illustratedis intended or should be inferred. The disclosure is intended to coverby the appended claims all such modifications as fall within the scopeof the claims.

The invention claimed is:
 1. A seat, comprising: a fabric seat surfaceformed from a woven fabric material, the fabric having heating elementfibers, the heating element fibers in electrical communication with aconductor; an overmolded carrier that is coupled to the fabric material;a frame defining a channel, wherein at least one the carrier and theconductor is attachingly fitted within the channel and holds the fabricmaterial in tension on the frame; and a connector in electricalcommunication with the conductor.
 2. The seat of claim 1, wherein theheating element fibers are woven into the fabric.
 3. The seat of claim2, wherein the heating element fibers are woven into the fabric todefine regions of slack in the heating element fibers.
 4. The seat ofclaim 2, wherein the fabric is woven from warp fibers and weft fibersand wherein the heating element fibers are disposed alongside the warpfibers.
 5. The seat of claim 1, wherein the carrier is disposed in thechannel in the frame.
 6. The seat of claim 1, wherein the conductor isdisposed in the channel in the frame.
 7. The seat of claim 5, whereinthe conductor is disposed in the channel.
 8. The seat of claim 1,wherein the conductor is a conductive strip.
 9. The seat of claim 8,wherein the strip is positioned in a strip socket, and wherein theheating element fibers are captured between the conductive strip and thestrip socket.
 10. The seat of claim 8, wherein the carrier and theconductor are overmolded onto the seat surface such that ends of theheating element fibers extend beyond a periphery of the carrier.
 11. Theseat of claim 1, wherein the carrier is formed in part by a conductivepolymeric material and in another part by a non-conductive polymericmaterial, the fabric being disposed between the conductive polymericmaterial and the non-conductive polymeric material, and wherein theheating element fibers extend into the carrier.
 12. The seat of claim 1,wherein some of the fabric is formed from monofilaments.
 13. The seat ofclaim 12, wherein the monofilaments are formed from a block copolymer.14. The seat of claim 1, wherein the heating element fibers have atargeted ohm resistance to achieve a temperature of about 30° C. toabout 50° C.
 15. The seat of claim 1, including a temperature sensor.16. The seat of claim 15, wherein the temperature sensor is a fiberincorporated into the seat surface.
 17. A seat, comprising: a fabricseat surface defined by a woven fabric material, the fabric materialcomprising heating element fibers, a frame defining at least onechannel; an overmolded carrier that is coupled to the fabric materialand holds the fabric material in tension on the frame; and a connectorin electrical communication with a conductor, wherein the heatingelement fibers are electrically coupled with the conductor, wherein thecarrier and the conductor are both at least partially disposed withinthe at least one channel of the frame, and wherein at least one of theconductor and the carrier is press fitted into the channel to hold thefabric material in tension.
 18. The seat of claim 17, wherein theheating element fibers are disposed between the conductor and areceiving element.
 19. A seat, comprising: a fabric seat surface formedfrom a woven fabric material, the fabric having heating element fibersand temperature sensor fibers, a frame including at least one channel;an overmolded carrier that is coupled to the fabric material and holdsthe fabric material in tension on the frame; and a connector inelectrical communication with a conductor, wherein the heating elementfibers and the temperature sensor fibers are in electrical communicationwith the conductor, wherein the heating element fibers are held in placeagainst the frame with the conductor, and wherein at least one of theconductor and the carrier is press fitted into the channel to hold thefabric material in tension.
 20. The seat of claim 19 further including aswitch that is electrically coupled with the heating element fibers, andwherein the temperature sensor fibers are configured to provide a signalto vary the temperature of the heating element fibers based on atemperature measured by the temperature sensor fibers.